Open Steel Decking Panels for Floors

HAISHENG manufactures these Open Steel Decking Panels for Floors using 12 fully automated cold-roll forming lines. Made from hot-dip galvanized steel strip, the panels serve the dual function of permanent formwork and tensile reinforcement for floor slabs. We provide an integrated supply of six categories of construction accessories, effectively resolving four common pain points: fragmented procurement, specification mismatches, on-site concrete leakage, and defective stud welding. We welcome your inquiries and orders.

Product Compliance and Traceability

1. National Standards for Panel Production: 

GB/T12755 (Manufacturing tolerances for profiled steel sheets); GB/T13912 (Testing for metallic zinc coatings)

2. National Standards for On-site Construction Acceptance: 

GB50018 (Code for design of steel structures); GB50205 (Code for acceptance of construction quality of steel structures)

3. National Standards for Galvanized Base Material: 

GB/T2518 (Continuously hot-dip zinc and zinc-alloy coated steel sheet and strip)

Selection Criteria

1 Base Material Grade Selection (Based on Requirements)

Panel Thickness Selection: Standard civil use (0.8–1.0 mm); General heavy-duty (1.2 mm); Extreme heavy-duty (1.5 mm). Thicknesses above 1.5 mm are not stocked and require custom ordering (12-working-day lead time).

2 Galvanized Coating Configuration (Zoned for Corrosion Protection)

1. Inland Dry Areas: Double-sided galvanizing (80–120 g/m²); 20-year design service life.

2. Coastal/Salt-Spray Areas: Mandatory double-sided hot-dip galvanizing (275 g/m²); prevents white rust on the panel surface for 3 years.

3. Acid/Alkali Chemical Areas: Heavy-duty galvanizing (450–600 g/m²); requires secondary protection with fire-resistant and anti-corrosive topcoats.

3 Concrete Topping Thickness Requirements

Uniform 100 mm pouring is strictly prohibited; thickness must be determined by panel profile: YX51 series topping ≥101 mm; YX76/75 series ≥126 mm. Insufficient thickness directly leads to slab cracking and excessive deflection.

4 Application Scenarios for Four Mainstream Panel Profiles

One-Stop Integrated Delivery

Unlike suppliers offering only Open Steel Decking Panels for Floors, HAISHENG provides a complete package—panels plus all accessories—from a single factory. This ensures zero-error dimensional matching and eliminates issues such as concrete leakage caused by incompatibility between market-sourced accessories and panel profiles.

1 Main Decking Specifications

- Standard stock lengths: 6/9/12m; custom lengths exceeding 15m require segmented transport.

- Mandatory lap requirements: Deck ends must extend ≥50mm onto the steel beam's top flange; unauthorized on-site shortening of lap length is prohibited and subject to mandatory inspection.

- Profile classification: Medium-rib (51mm) for civil use; high-rib (75/76mm) for heavy-duty industrial use; do not mix types.

2 Shear Stud Anchoring System

- Stud material: ML15 specialized structural steel (prevents fatigue fracture common in ordinary carbon steel studs).

- Specification matching: YX51 pairs with φ16×80 studs; YX76 pairs with φ19×90 studs; cross-model mixing is strictly prohibited.

- Construction accessories: Full rental packages include ceramic ferrules and inverter stud welding machines; mandatory stud spacing ≤600mm.

3 Edge Sealing & Grout Leakage Prevention

- End closures: Specific models for 51/76 profiles; made of galvanized steel matching the decking; on-site fabrication using sheet metal is prohibited (due to rust/detachment risks).

- L-shaped edge flashing: For sealing cantilevered slabs, elevator openings, and ventilation shafts.

- Gap sealing: Butyl sealant; suitable for 0–5mm gaps between panels; resistant to concrete alkalinity.

4 Decking Fixation & Reinforcement Accessories

- Primary fixation: Full-penetration spot welding at ends; through-deck spot welding for studs; interlocking side seams combined with intermittent spot welding at 500mm intervals.

- Local reinforcement: φ4.8 galvanized self-drilling screws; used only for reinforcing openings, corners, or deflection points; not for primary structural fixation.

5 Standardized Reinforcement Scheme for Cast-in-Place Concrete

- Top-layer anti-crack main reinforcement: Φ10–Φ12 @ 200–250mm; continuous layout along the span to prevent surface shrinkage cracks.

- Transverse distribution reinforcement: Φ8 @ 250mm; arranged perpendicular to main reinforcement to disperse concentrated loads. Special Reinforcement: Radial reinforcement added at openings; φ6 steel mesh laid on heavy-load floors to minimize future slab settlement.

6. Specifications for Dedicated Temporary Shoring for Open-Rib Decking

- Shoring Trigger Threshold: Shoring is mandatory for clear spans >2.5m; no exceptions allowed.

- Shoring Types: Portal-frame steel shoring (for rapid installation); full-bay steel pipe scaffolding (for extra-large spans).

- Removal Criteria: Removal permitted only after field-cured concrete test specimens reach 75% of design strength and measured deflection is ≤L/250.

Cross-Category Comparative Analysis

I. Core Differentiated Advantages

1. Lower Raw Material Procurement Costs: For the same slab thickness and rib height, Open Steel Decking Panels for Floors require 12%–18% less material (unfolded width) and offer greater coverage per ton, reducing the main material budget for large-area flooring by 7%–11%.

2. Zero-Cost On-Site Openings: Open rib channels eliminate the need for specialized hole-cutting tools; utility and equipment openings can be cut via gas cutting. They adapt well to irregular or curved floor plans, with offcut utilization rates reaching up to 92%.

3. High Stud Welding Pass Rate: Unobstructed ribs allow for vertical welding gun positioning, achieving a 99% pass rate (compared to a >15% rework rate for cold-lap/incomplete fusion in closed-rib decking).

4. Strong Concrete Interlock Stability: Trapezoidal open ribs create a mortise-and-tenon effect, increasing concrete bond strength by 23% and preventing steel-concrete delamination during seismic events.

5. Reduced Load on Main Structure: 8% lighter dead weight for the same coverage area allows for smaller steel beam and column cross-sections, reducing total structural steel consumption by 3%–5%.

6. Convenient Post-Installation Maintenance: Open bottom ribs allow for the direct installation of hanger rods and ceiling suspension points without damaging the panel's galvanized coating.

7. Short Delivery Lead Times: Simple roll-forming die structure enables production speeds of 8–15 m/min; ample stock ensures full-truckload shipment within 3 days.

II. Three Objective Drawbacks and Mitigation Strategies

1. Limited unsupported span: Maximum unsupported span is only 2.4m. Mitigation: Pre-plan temporary supports; HAISHENG provides complimentary support layout drawings.

2. Weak fire resistance: Bare panel rating is 0.25h; composite slab rating is 1.0–1.5h. Mitigation: Apply a 10mm thick ultra-thin fire-retardant coating to the panel surface to meet Class II fire safety requirements.

3. Poor underside aesthetics: Ribbed profile requires a suspended ceiling for concealment. Mitigation: Supply custom ceiling furring channels designed for the rib profile to shorten the ceiling installation schedule.

Factory End-to-End Quality Control Process

1. Dual-check raw material intake

- Documentation verification: Check original mill material certificates and third-party zinc coating test reports; reject untraceable loose coils.

- On-site sampling: Randomly sample 1 out of every 5 coils of Open Steel Decking Panels for Floors to test yield strength and zinc coating weight; reject coils with wavy edges or camber (curvature).

- Pre-slitting: Cut raw material width according to the specific panel profile to prevent profile misalignment during forming.

2. Precision control during production line forming

- Leveling process: 13–19 roller multi-directional leveling to eliminate internal coil stress; surface flatness maintained at ≤2mm/m.

- Roll forming: 18–26 sets of progressive rollers for cold forming at ambient temperature; zero high-temperature processing protects the zinc coating, preventing coating delamination.

- Strict adherence to national tolerances: Rib height ±1.0mm, rib pitch ±1.5mm, panel width ±2mm; items exceeding tolerances are scrapped or reworked.

3. Cutting and post-processing details

- PLC-controlled flying shear cutting: Length error ≤2mm for panels up to 10m; cuts are free of rolled edges or burrs.

- Manual grinding: Smooth out any upturned zinc coating at cut edges to prevent premature rusting; simultaneously cut matching end caps and edge trims from the same batch to ensure consistent zinc coating specifications.

4. 6 Mandatory Factory Inspections

Full inspection of geometric dimensions; visual inspection of panel surface appearance; sampling for double-sided zinc coating weight; coating adhesion test via 180° rib bending; individual panel warpage check; verification of model and batch number markings.

5 Storage, Packaging, and Protection

Layered stacking by specification; galvanized corner protectors at ends to prevent transit damage; 6-meter panels strapped with 3 steel bands per bundle; stored in a temperature-controlled, dry indoor warehouse to prevent moisture exposure and "white rust" associated with outdoor storage.

Measured Mechanical and Durability Parameters

1 Self-weight and Sectional Stiffness Parameters for Main Profiles

2 Maximum Unsupported Span

Test conditions: 120mm cast-in-place concrete; construction live load 2.0 kN/m²; deflection ≤ L/180

- YX51: 0.8mm = 2.1–2.3m; 1.0mm = 2.4–2.7m; 1.2mm = 2.8–3.0m

- YX76: 1.0mm = 2.8–3.2m; 1.2mm = 3.3–3.6m (upper span limit for open-profile decking)

3 Load-bearing, Fire Resistance, and Durability

- Service-stage load capacity: Standard flooring 3.5–5.0 kN/m²; heavy-duty capacity up to 8 kN/m² with thicker base steel + concrete

- Deflection standards: Construction ≤ L/180; Service ≤ L/250

- Durability: 25–30 years (Z275 galvanization in normal inland environments)

- Fire resistance rating: Composite steel-concrete 1.0–1.5h; bare deck 0.25h

Quick Selection Guide for Procurement

1. Standard office buildings/indoor mezzanines: YX51-305-915 profile + 0.8/1.0mm base steel + φ16 shear studs + YX51-type end closures + top reinforcement mesh; no full-span shoring required.

2. Heavy-duty warehousing/heavy industrial workshops: YX76-344-688 profile + 1.2/1.5mm base sheet + φ19 shear studs + Type 76 end closures + double-layer, two-way reinforcement + full-span temporary shoring.

FAQ

1. Q: Can Open Steel Decking Panels for Floors for floors replace the bottom tensile reinforcement of the floor slab?

A: They can replace the bottom tensile reinforcement provided that the reinforcement meets national standards; however, the top anti-crack reinforcement cannot be omitted and must be separately specified in the design drawings.

2. Q: Does cutting stock material damage the galvanized anti-corrosion coating?

A: Online flying shear cutting causes no high-temperature burn marks; only the cut end face exposes raw steel, and the zinc-rich paint supplied with the shipment allows for on-site touch-ups.

3. Q: What is the delivery lead time for cross-regional supply?

A: Standard stock items ship as full truckloads within 3 days; custom profiles take 7–12 days. Direct shipping is available to major cities across the country for mainstream steel structure projects.